MXPA06012167A

MXPA06012167A - Wall block system.

Info

Publication number: MXPA06012167A
Application number: MXPA06012167A
Authority: MX
Inventors: Robert Macdonald; William Dawson
Original assignee: Keystone Retaining Wall System
Priority date: 2004-04-29
Filing date: 2005-04-28
Publication date: 2007-01-17
Also published as: US20050252145A1; EP1740783A1; CN1946909A; WO2005108698A1

Abstract

A system of blocks having a stacking block and a corner block configured to fit together in the construction of a wall. The blocks interlock with each other so that no mortar is required in the construction of a wall. Additional pin reinforcement can be added.

Description

fractured concrete surface that looks like a natural split rock. In another commonly used method, the blocks are formed individually in a mold and the surfaces are textured by the removal of the mold. Another method is to form the blocks in pairs and split or separate the block, resulting in a rough surface. Additional machine texturing processes can also be applied. Blocks produced in this way can be used to build independent walls and walls that have sharp corners (ie, 90 degree angles) with a natural appearance on all exposed sides. There is a need in this technique for a block system that is easy to install and can be used to build walls, wall corners, fences, columns, pillars, robust pilasters without mortar, or other structures that have the desired appearance. BRIEF DESCRIPTION OF THE INVENTION This invention is a block system comprising a stacking block and a corner block configured to fit together in the construction of a wall. The blocks interlocked with each other in such a way that no mortar is required in the construction of a wall. Additional reinforcement can be added with bolts. BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a perspective view of a stacking block according to this invention. Figure 2 is a top view of the stacking block of Figure 1. Figure 3A and Figure 3B are end views of the stacking block of Figure 1. Figure 4A and Figure 4B are top and end views, respectively, of a pair of stacking blocks formed in a mold. Figure 5A and Figure 5B are perspective and top views, respectively, of an alternative stacking block of this invention. Figure 6A and Figure 6B are perspective and top views, respectively, of an alternative stacking block of this invention. Figure 7 is a bottom perspective view of a corner block according to this invention; 'Figure 7B is a bottom view; Figure 7C is a top perspective view of the corner block with the recessed area and a hole shown in a faded form; Figure 7D is a top view. Figure 8A is a bottom perspective view of a corner block in accordance with this invention; Figure 8B is a top perspective view of the corner block with the recessed area and orifice shown in a faded form; Figure 8C is a bottom view; ^ Figure 8D is a top view. Figure 9A and Figure 9B are top and side views, respectively, of the corner blocks of Figures 7 and 8 after they are removed from a mold. Figure 10A, Figure I0B and Figure 10C are perspective views of portions of a column, a corner of a wall and a wall respectively, constructed from the stacking and corner blocks of this invention. Figure 11A and Figure 11B are perspective views of pairs of stacking blocks, and Figure 11C and Figure 11D are perspective views of portions of walls using pairs of stacking blocks. Figure 12 is an end view of two sets of stacking blocks after they are removed from their molds. Figure 13A is a perspective view of a cover or cap block and Figure 13B and Figure 13C are end views of a stacking block with a cover or cap layer. Figure 14A, Figure 14B, Figure 14C and Figure 14D are end views of cover or cap layers.

DETAILED DESCRIPTION OF THE INVENTION In this application ', "upper" and "lower" refer to the placement of a block when a structure is constructed. The lower or lower surface of the blocks is the surface that faces the ground. The blocks of this invention can be made of a rough and weather resistant material such as concrete. Other suitable materials include plastic, forced fibers such as fiberglass, wood, metal and stone. Instead of being formed from a solid mass of material, the blocks can be hollow. This is an advantage in saving materials and handling the block. These hollow shell blocks may be formed of urethane or concrete or by casting techniques. The surface of the blocks may be smooth or may have a rough appearance, such as that of natural stone. The blocks are formed into molds and various textures can be created on the surface, as is known in the art. The blocks of this invention have interlocking elements or projections to hold the blocks in place and to eliminate the need for mortar when the blocks are stacked on top of each other. In blocks manufactured conventionally, the height of the blocks tends to vary a little and that variation is counteracted using mortar to level rows and stacks of blocks. Preferred blocks for use in this invention are formed on one end (rather than on one side) which allows the blocks to be formed with great precision, thus allowing the blocks to interlock without mortar. Suitable (and preferred) stacking blocks are described in the US patent. No. 6,176,049 (Crant et al.), Incorporated herein by reference. The stacking blocks have opposite upper and lower surfaces having corresponding channels and projections such that the blocks interfere when stacked. The stacking blocks of this invention can have several dimensions. This invention is a block system that incorporates two different types of blocks: a stacking block and a corner block. Each of these blocks comes in two forms, a right block and a left block, which are used in alternating tons during the construction of a wall as described in more detail below. The first type of block, the stacking block, has a projection on the upper surface that is interlocked with corresponding grooves on the lower surface of an overlapping block. This block can have several dimensions. The stacking block is provided in full and half sizes, and each is provided in right and left versions. The block is configured in such a way that the blocks can be stacked together uniformly. The second type of block, the corner block, is a rectangular block having a sunken area configured to interlock with the stacking block. The stacking blocks that are placed adjacent to the corner blocks are provided with projections having at least one recess so that a stacking block on one side of a corner can receive the lower surface of a stacking block superposed on the other side of the corner in a way that will be described more fully later. The corner block is also provided with a hole for use as a bolt connection system as described more fully below. The block system of this invention can take several forms. In its most basic form, the system includes left and right stacking blocks as shown in Figures 4A and 4B, and left and right corner blocks as shown in Figures 7A and 8A, respectively. Alternatively, the left and right stacking blocks can be combined into a single stacking block that incorporates two cavities (ie, the right and left cavities) in the upper projection of the block. A wall or column can be constructed with this basic system using stacking blocks either right or left randomly to form the wall or column except in positions adjacent to corner blocks where left and right stacking blocks could be used in alternating stacks as described later. Corner portions of the wall or column can be formed using alternating right and left corner blocks, as also described later. The system may further include another block mode, a medium sized stacking block as shown in FIGS. 6A and 6B. This medium-size stacking block is used, for example, when a wall meets a vertical surface to maintain a pattern of uncoupled engagement of blocks in the wall. The system may further include double width stacking blocks as shown in Figures 11 to 12, which are used as foundation blocks, and / or to construct pilasters in the wall as will be more fully described below. Figures 1 to 4 illustrate the stacking blocks of this invention. The block 100a has opposed upper and lower surfaces 104 and 105, opposed side surfaces 106 and 107, and opposed end surfaces 102 and 103. The distance between the end surfaces 102 and 103 defines the length of the block. The distance between the lateral surfaces defines the width, and the distance between the upper and lower part defines the thickness of the block. Through the center of the block along the length is the core 108 through which a longitudinal axis is. The upper surface 104 has channels / grooves 110a and 112a adjacent to each side surface defining a raised portion therebetween. Channel 110a has additional Illa cavities. The lower surface has projections 114 adjacent to each lateral surface. When stacked, the projections on the lower surface of a block fit into the channels on the upper surface of an underlying block. Thus, these blocks interlocked. The intermeshing eliminates any need for mortar to join the stacked hollow blocks 100a together. It should be understood that the designations "superior" or "winferior" are arbitrary and that the blocks can be stacked in the opposite orientation.The edges of the blocks can be chamfered or bevelled to provide an attractive appearance, and preferably the edge formed by the channel or slot in the upper surface with the side surface is chamfered Figures 4A and 4B illustrate how the blocks are seen after they are cast and removed from the mold It is convenient to mold the blocks into identical pairs of images, ie the block 100a is shown on the left and block 100b is shown on the right.The blocks are identical except for the location of the sunken area 111 a / b.The stacking blocks are conveniently formed in pairs 120, with slots 125 along the the upper surface, as shown in Figures 4A and 4B, the pair of blocks is split along the slot 125 to form a single block. in this way it forms a rough surface of the split side surfaces. The rough surface is a desirable appearance for walls and corners where the side of the block will be seen. Figure 5A and Figure 5B illustrate another embodiment of the block. Block 200 is similar to blocks 100a and 100b, but there are two contiguous cavities with the channels on top of the block. Thus, this block could be used with either a right or left corner block, as described below. The block 200 has opposed upper and lower surfaces 204 and 205, opposed side surfaces 206 and 207, and opposed end surfaces 202 and 203. The distance between the end surfaces 202 and 203 defines the length of the block. The distance between the lateral surfaces defines the width, and the distance between the upper and lower part defines the thickness. Through the center of the block along the length is the core 208. The upper surface has channels or slots 210 adjacent each side surface defining a raised portion therebetween and each channel having additional cavities 211. The lower surface has projections 214 adjacent to each lateral surface. These blocks can be stacked together with 100 a / b blocks and with corner blocks when building a wall, as described below. The stacking blocks can be made in any desired dimension, however, a convenient and attractive size for these blocks is approximately 15.2 centimeters wide and high, and 20.3 centimeters long. The core measures approximately 8.9 centimeters in diameter. The channels and projections are approximately 2.5 centimeters wide. The stacking block 300 shown in FIGS. 6A and 6B is a "half block", that is, having the same width as the block 100a, but about half the length (about 10.2 centimeters). This is a convenient size to use when forming a corner structure with stacking blocks and full-length corner blocks. The half-block allows the wall to be constructed with a tie pattern by off-center engagement from inlet to pile while maintaining a vertical end to join the vertical surface as shown in Figure 10C. The block 300 has opposed upper and lower surfaces 304 and 305, opposite lateral surfaces 306 and 307 and opposite end surfaces 302 and 303. The distance between the end surfaces 302 and 303 defines the length of the block.

The distance between the lateral surfaces defines the width, and the distance between the upper and lower part defines the thickness of the block. Through the center of the block along the length is the core 308 through which a longitudinal axis is. The upper surface has channels or grooves 310 adjacent each side surface defining a raised portion therebetween. The lower surface has projections 314 adjacent to each lateral surface. These blocks are stacked together with 100 a / b blocks and with corner blocks when building a wall, as described below. Figures 7 to 9 show a corner block 500 a / b. This block has a rectangular shape and has a sunken area on the bottom of the block configured to conform with the stacking blocks of that invention. The corner block is provided in both right and left versions, that is, identical images. Figures 7A to 7D show the right block 500a and the figures 8A to 8D show al. left block 500b. Block 500 a / b has opposite top and bottom surfaces 504 a / b and 505 a / b, opposite side surfaces 506 a / b and 507 a / b, and opposite end surfaces 502 a / b and 503 a / b. The distance between the end surfaces 502 a / b and 503 a / b, defines the length of the block. The distance between the lateral surfaces defines the width, and the distance between the upper and lower part defines the thickness of the block. The bottom 505 a / b of the block is provided with a recessed area 515 a / b, configured in such a way that a portion of the upper surface of a stacking block fits or fits therein. Figure 7C and Figure 8B show the bottom of the block in faded form. The hole 513 a / b, shown in faded form in Figure 7A and Figure 8B, extends through the thickness of the block and is configured to receive the bolt 900, as indicated in Figure 10A. The bolt 90 comprises a shaft 91 and a head 92. The head 92 extends over the upper surface of the block and fits within the hole of an overlying block. Thus, the hole has a diameter at the bottom of the block sufficient to receive the head of a bolt that has been placed in the hole of an underlying block. A preferred means for joining blocks of adjacent sheets together is a bolt having a head portion, however, it should be understood that a cylindrical element such as a rod, having a desired length, can be used to join two or more blocks together. Figure 9A and Figure 9B show the assembly 520 of corner blocks after their removal from a mold. Figure 9B shows holes 513a and 513b in faded form in the side view of the block. It is convenient to form blocks four at a time, and in identical pairs. Separation planes 525 and 527 are provided along which the blocks are split. Typically, a rough surface is formed when the blocks are split. Figure 10A shows the column 900 constructed with blocks 100a and 500b of this invention, and illustrates how the blocks can be adjusted and joined. For example, a first corner block 500b is placed near the stacking blocks 100a in the lower block stack. In the second block stack, the corner block 500b is rotated 90 degrees and placed on a portion of a stacking block and a portion of the first corner block. The cavity in the second corner block fits over the exposed upper surface of the stacking block. The holes in the first and second corner blocks are coincident, so that one bolt can be installed, locking the blocks more together. A portion of the wall 910 is shown in Figure 10B, which also illustrates that blocks that do not have cavities in the upper part of the block can be used to construct a wall. To stack blocks uniformly at the corners, the corner blocks 500 a / b and the stacking blocks (ie, 100 a / b, 200 and 300) are used together to form the corners. Figure 10C shows a wall 920 and illustrates the use of half blocks 300 and blocks 100 a / b to form a latch pattern. Figure 11A to Figure 11D illustrate units of double blocks and how these units are used to form pilasters and / or reinforce a wall. For reasons of simplicity in the drawing, blocks which do not have cavities are shown in the drawings; however, it should be understood that any stacking block described above can be used to form a wall or a pilaster. The blocks are cast in pairs. As described above, the separation of the blocks forms a desirable surface appearance. Occasionally, it is convenient to use pairs of blocks that are not broken to reinforce a wall and / or form a pilaster. Figure 11A shows a pair of blocks 420 that can be split in the separation plane 425 to form blocks 400. These blocks are similar to block 100 a / b, except that they do not have a cavity corresponding to the cavity 111 a / b , for example. Figure 11B illustrates the pair of blocks 120 with their separation plane 125. Figure 11C illustrates how the wall 930 can be formed by stacking double block units together with individual blocks (in this case, blocks 400 and units 420). This provides the reinforcement of the wall and increases its structural integrity. Figure 11D shows an insulated wall 940 comprising blocks 400 and units 420. The wall 940 has a lower floor that comprises units of double blocks 420. These units are placed on the base layer 490, and then the wall is constructed both of individual blocks 400 as double block units 420. Stacking units 420 on each form a pilaster and have the appearance of a column. The pilasters reinforce the structure of the wall, making it resistant to being knocked down by the wind. The number and frequency of pilasters in a wall is determined by a structural analysis based on the geometry of the wall, its weight and the forces acting to bring down the wall. Figure 12 illustrates two sets of stacking blocks 450 that have been removed from a four-block mold and shows how sets of blocks can be stacked together. They can be split into single or double blocks along separation planes 452, 454 and 456. The choice of the separation plane is determined by the desired appearance for the blocks. For example, the outer surfaces 433 are smooth compared to the rough surfaces formed by splitting pairs of blocks. Individual blocks and two and three sets of blocks can be formed by splitting block set 450 as desired. Similar to that described above for Figure 11D in which two block units are used, three or four block units can be used to form pilasters in a wall. Fig. 13A shows a cover block 80a and Fig. 13B shows a stacking block 100 a / b with an end block 80a. The recessed area 84a is dimensioned to receive the stacking block. The end block fits over the upper part 104 a / b of the block and has sides 87a which coincide with sides 106/107 of the block. Figure 13C shows a different style of auction block 80b, since it has the edge or projection 87b extending beyond the sides of the block. Figures 14A to 14D show various styles of auction blocks 802a to 802d, each of which has recessed areas 804a to 804d, respectively, to fit over underlying blocks. Finishing blocks provide a finished appearance to a fence, pilaster, column or wall. The finishing blocks can be provided in various lengths, typically of a convenient size to handle. Typically, in the construction of a wall, several finishing blocks will be used to form a cover or cap layer through the upper part of the wall. At the end of the wall, where the end of the auction block could be seen, the finishing block has a finished surface, that is, it is closed at one end. The style of the cover layer or auction is a matter of design choice. Cover or top layers can be made of any material, including wood, concrete and polymeric materials. Although particular embodiments have been described herein in detail, this has been done for reasons of illustration only, and is not intended to be limiting with respect to the scope of the claims. In particular, it is contemplated that various substitutions, alterations and modifications may be made to the invention without departing from the spirit and scope thereof as defined by the claims. For example, the choice of materials or variations in the shape or angles at which some of the surfaces intersect is believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments described herein. It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims

Having described the invention as above, the content of the following claims is claimed as property: 1. A system of blocks for constructing a wall having a corner, characterized in that it comprises: a plurality of stacking blocks having upper and lower surfaces opposite, first and second opposite lateral surfaces and first and second opposite end surfaces, upper and lower surfaces, lateral surfaces and end surfaces define together a body of the block, at least one of the upper and lower surfaces has a projection extending from the same, the other of the upper and lower surfaces has a channel formed therein, the stacking blocks being configured to be stacked in piles to form a wall, in such a way that a projection extending from a stacking block in a first ply is received in a slot of a stacking block in an adjacent plinth and a plurality of corner blocks having opposite upper and lower surfaces, first and second opposed side surfaces and first and second opposed end surfaces, the upper and lower surfaces of the corner block, side surfaces of the corner block and end surfaces of the block of corner define together a body of the corner block, the corner blocks being configured to be stacked in plyings to form a corner of the wall, at least one of the upper and lower surfaces of the corner block has a recessed portion configured to receive a projection extending from one stacking block, the other of the upper and lower surfaces of the corner block being substantially smooth. 2. The block system according to claim 1, characterized in that the upper and lower surfaces of the corner block each have a hole.
3. The block system according to claim 2, characterized in that the corner blocks are configured in such a way that, in forming the wall, a hole in a corner block in a first floor receives a bolt placed in a hole in the wall. a corner block in an adjacent wall.
4. The block system according to claim 1, characterized in that the depressed portions on the stacking blocks are configured to form left and right wall blocks.
5. The block system according to claim 1, characterized in that the stacking block is a medium size stacking block.
6. The block system according to claim 5, characterized in that, when forming the wall, the medium size stacking block is configured to be used when the wall meets a vertical surface.
7. A system of blocks for constructing a wall having a corner, characterized in that it comprises: a plurality of stacking blocks having opposite upper and lower surfaces, first and second opposed side surfaces and first and second opposed end surfaces, the upper surfaces and bottom, side surfaces and end surfaces define a body of the block together, the top surface has a projection extending therefrom, the bottom surface has a channel formed therein, the stacking blocks being configured to be stacked in layers to form a wall, in such a way that a projection extending from a stacking block in a first ply is received in a slot. a stacking block in an adjacent overlay and a plurality of corner blocks having opposite top and bottom surfaces, first and second opposite side surfaces and first and second opposite end surfaces, the top and bottom surfaces of the corner block, side surfaces of the corner block and end surfaces of the corner block define together a body of the corner block, the corner blocks being configured to be stacked in plyings to form a corner of the wall, the lower surface of the corner block having a recessed portion configured to receive a projection extending from a stacking block, the upper surface of the block corner being substantially smooth. The block system according to claim 7, characterized in that the corner block has a hole. 9. The block system according to claim 8, characterized in that the corner blocks are configured in such a way that, when the wall is formed, the hole in a corner block in a first wall receives a bolt placed in the hole of the wall. a corner block in an adjacent wall. The block system according to claim 7, characterized in that the depressed portions on the corner blocks are configured to form left and right corner blocks. The block system according to claim 7, characterized in that the stacking block is a medium size stacking block. 12. The block system according to claim 11, characterized in that, when forming the wall, the medium sized stacking blog is configured to be used when the wall meets a vertical surface. 13. A corner blogue characterized in that it comprises: opposite upper and lower surfaces, first and second opposite lateral surfaces and first and second opposite end surfaces, upper and lower surfaces, lateral surfaces and end surfaces define together a body of the block, the blog of corner being configured to be stacked in piles to form a corner of a wall, at least one of the upper and lower surfaces has a recessed portion configured to receive a projection extending from one stacking blog, the other of the upper surfaces and lower being substantially smooth; wherein the stacking block has opposite upper and lower surfaces, first and second opposed side surfaces and first and second opposed end surfaces, the upper and lower surfaces of the stacking block, side surfaces of the stacking blog and end surfaces of the stacking block Together they define a body of the stacking block, at least one of the upper and lower surfaces of the stacking block has a projection extending therefrom, the other of the upper and lower surfaces of the stacking block has a channel formed in the stacking block. same, the stacking blocks being configured to be stacked in piles to form the wall, such that a projection extending from a stacking block in a first ply is received in a slot of a stacking block in an adjacent ply . 1 . The corner block according to claim 13, characterized in that it also has a hole. 15. The corner block according to claim 14, characterized in that, in forming the wall, the hole in a corner block in a first floor receives a bolt placed in the hole of a corner block in an adjacent floor. 16. The corner block according to claim 13, characterized in that the depressed portions on the corner blocks are configured to form left and right corner blocks. 17. A column characterized in that it comprises: a plurality of corner blocks having opposite upper and lower surfaces, first and second opposed side surfaces and first and second opposed end surfaces, the upper and lower surfaces of the corner block, side surfaces of the block of corner and end surfaces of the corner block define together a body of the corner block, the corner blocks being configured to be stacked in rows to form the column, at least one of the upper and lower surfaces of the corner block has a sunken portion configured to receive a projection extending from a stacking block, the other of the upper and lower surfaces of the corner block being substantially smooth and a plurality of stacking blocks having opposite upper and lower surfaces, first and second surfaces opposite sides and first and second end surfaces more opposite, the upper and lower surfaces of the stacking blocks, side surfaces of the stacking blocks and end surfaces of the stacking blocks define together a stacking block body, at least one of the upper and lower surfaces of the blocks of stacking has a projection extending therefrom, the other of the upper and lower surfaces of the stacking blocks has a channel formed therein, the stacking blocks being configured to be stacked in piles to form the column, such that a projection extending from a stacking block in a first ply is received in a slot of a piling block in a second ply adjacent to the first ply; wherein the first ply has at least a first stacking block placed near at least a first corner block and the second ply has at least a second stacking block placed near at least a second corner block, the second block of The corner is rotated about a vertical axis of the column in relation to the orientation of the first corner block, whereby the portion recessed in the second corner block fits over the projection of the first stacking block. The column according to claim 17, characterized in that the second corner block is rotated 90 degrees about a vertical axis of the column in relation to the orientation of the first corner block. 19. The column according to claim 17, characterized in that each corner block has a hole. 20. The column in accordance with the claim 19, characterized in that the hole in a first corner block receives a bolt placed in a hole of the second corner block. 21. A wall having a corner, characterized in that it comprises: a plurality of stacking blocks having opposite upper and lower surfaces, first and second opposed side surfaces and first and second opposed end surfaces, the upper and lower surfaces, lateral surfaces and end surfaces define a body of the block together, at least one of the upper and lower surfaces has a projection extending therefrom, the other of the upper and lower surfaces has a channel formed therein and a plurality of corner blocks which have opposite upper and lower surfaces-, first and second opposite side surfaces and first and second opposite end surfaces, the upper and lower surfaces of the corner block, side surfaces of the corner block and end surfaces of the corner block define a body together of the corner block; wherein the stacking blocks are configured to be stacked in piles to form the wall, such that a projection extending from a stacking block in a first ply is received in a slot of a stacking block in an adjacent ply and wherein the corner blocks are configured to be stacked in plyings to form the corner of the wall, at least one of the upper and lower surfaces of the corner block has a recessed portion configured to receive a projection extending from a block of stacked, the other of the upper and lower surfaces of the corner block being substantially smooth. 22. The wall having a corner according to claim 21, characterized in that the upper and lower surfaces of the corner block each have a hole. The wall having a corner according to claim 22, characterized in that a hole in a corner block in a first floor receives a bolt placed in a hole of a corner block in an adjacent floor. 24. The wall having a corner according to claim 21, characterized in that the stacking block is a medium size stacking block. 25. The wall having a corner according to claim 24, characterized in that, when forming the wall, the medium sized stacking block is to be used where the wall meets a vertical surface.